Smart machine tool system

ABSTRACT

A machine tool system ( 30 ) includes a tool ( 32 ) for cold forming a workpiece over an operating cycle and a sensor device ( 40 ) which senses each operating cycle of the tool ( 32 ). Identification data for the tool ( 32 ) and operating data for the tool ( 32 ) are stored on an electronic device ( 34 ) fixedly mounted to the tool ( 32 ). At least one interface device ( 46 ) provides communication between the electronic device ( 34 ) and the sensor device ( 40 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This is the national stage of International Application No.PCT/US01/06379 filed Feb. 28, 2001. This is a provisional applicationSer. No. 60/186,169 filed on Feb. 29, 2000

BACKGROUND OF THE INVENTION

This invention relates generally to methods and apparatus forgundrilling (deep hold drilling) or cold forming workpieces ongundrilling machines, heading machines, or thread rolling machines,including combination machines like bolt making machines.

In thread rolling dies to which the invention relates, workpieces aretransformed into finished screws by a rolling process as the workpiecespass between a pair of elongated generally planar dies. One of the diesis stationary, and the other die is displaced relative to the other toproduce a surface material flow on the workpiece to thereby form acontinuous helical thread path on the screw. In the thread rolling diemachines for which the invention has particular applicability, a shorterdie of a pair of dies is held in stationary relationship while thelonger die is moved in a direction generally parallel to a longitudinalreference plane. The axis of rotation of the body of the workpiecetravels longitudinally as the workpiece rolls between the pair of dies.The diameter of the finished thread is controlled by the diameter of theworkpiece and the distance between the dies at the finished end of thestroke. The dies are configured so that as the workpiece rolls acrossthe dies, the desired threading is formed on the workpiece. Threadrolling is also accomplished using cylindrical or planetary dies andmachines and this invention is applicable to all known configurations.

To be competitive in the marketplace, manufacturers must maintain a costeffective manufacturing environment and must be responsive to customerrequests. These two goals can often be in conflict. For example, costsmay be reduced by maintaining low inventories of raw materials, finishedproducts, and tooling. However, if such inventories are too low, themanufacturer may be unable to promptly respond to a customer order.Manufacturers typically strike a balance where they maintain someminimum inventory of raw materials and/or finished product such that ahypothetical order may be filled within an acceptable time period. Suchmanufacturers also monitor their tooling to ensure that new tooling isreceived just as the old tooling reaches the end of its effectivelifetime.

Each set of tools has an effective lifetime which is defined by amaximum number of operating cycles which may be performed before theaccumulated wear precludes further use. There are several factors whichmay change the effective lifetime of a tool set. For example, the rateof tool wear is proportional to the material hardness of the workpieces,where the rate of die wear increases as the material hardness increases.Consequently, the effective lifetime of a die set which is used to formthreads on workpieces composed of relatively hard stainless steel islower than the effective lifetime of an identical die set which is usedto form threads on workpieces composed of relatively soft carbon steel.

Effectively monitoring the effective lifetime of tool sets which areutilized to produce many short production runs and/or which are utilizedto produce components composed of different materials can beproblematic. Although the number of components produced in each run orof each material may be fairly easily determined, conventional recordkeeping systems for tracking the effective lifetime of the tool set arecumbersome, resulting in errors which can be quite costly to themanufacturer and supplier.

SUMMARY OF THE INVENTION

Briefly stated, the invention in a preferred form is a machine toolsystem including a tool for cold forming a workpiece over an operatingcycle. The tool has an electronic device fixedly mounted thereto whichincludes means for storing identification data for the tool andoperating data for the tool. The system also includes a sensor devicewhich senses each operating cycle of the tool and at least one interfacedevice which provides communication between the electronic device andthe sensor device.

Preferably, the electronic device is encased in sealant material withina recess in an exterior surface of the tool. The electronic device mayhave an antenna extending within the sealant material or an electricalor fiber optic lead extending through the sealant material to thesurface of the tool.

The machine tool system interface device generally includes a processmonitoring system having a key pad, a monitor, and a microprocessor. Theprocess monitoring system may include a temperature sensor for measuringthe temperature of the tool and/or a flow detector for monitoring theflow of coolant to the tool. The interface device also generallyincludes a portable electronic reader. The portable electronic readerincludes a first data transmission interface for sending and receivingsignals to the electronic device, memory for storing the signalsreceived from the electronic device, and a second data transmissioninterface for transmitting the stored signals to the process monitoringsystem. The portable electronic reader may also includes a display forviewing the signals received from the electronic device.

The machine tool system provides a means for monitoring the life cycleof the tool. Each cold forming tool has a lifetime which can beexpressed as the number of operating cycles which can be expected fromthe tool before such tool no longer operates properly or efficiently.The sensor device senses each operating cycle of the tool and transmitsoperating cycle data to the electronic device, where such operatingcycle data is stored. The identification data and the operating cycledata stored in the electronic device is accessed by the monitoringsystem or the portable electronic reader and is used to calculate thenumber of operating cycles that the tool has been used. Subtracting thenumber of operating cycles that the tool has been used from the expectednumber of operating cycles over the lifetime of the tool provides ameasure of the remaining lifetime of the tool.

It is an object of the invention to provide a machine tool system thatautomatically monitors the tool usage, facilitating determination of theremaining tool lifetime.

It is also an object of the invention to provide a machine tool systemthat facilitates identification and inventory of multiple tools.

Other objects and advantages of the invention will become apparent fromthe drawings and specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be better understood and its numerous objectsand advantages will become apparent to those skilled in the art byreference to the accompanying drawings in which:

FIG. 1 is a schematic diagram of a first embodiment of a machine toolsystem in accordance with the invention;

FIG. 2 is a partly schematic top view of the machine tool of FIG. 1comprising a short stationary die and a long displaceable die in amatched position, the stationary die having a recess containing amicrochip;

FIG. 3 is a schematic diagram of a second embodiment of a machine toolsystem in accordance with the invention;

FIG. 4 is a partly schematic top view of the machine tool of FIG. 2comprising a stationary short die and a displaceable long die in amatched position, the stationary die having a recess containing a sensorand/or a microchip and/or a piezo electric power source;

FIG. 5 is a schematic view of the hand-held electronic reader of FIGS. 1and 3;

FIGS. 6 a through 6 d are a schematic representation of a cold headingprocess utilizing a third embodiment of a machine tool system inaccordance with the invention; and

FIG. 7 is a perspective view, partly in section, of a gun drillingmachine utilizing a fourth embodiment of a machine tool system inaccordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to the drawings, wherein like numerals represent likeparts throughout the figures, a stationary die 10 and a moveable die 12are employed to roll a thread on a workpiece to produce a finished screwby a reciprocating flat die method. The reciprocating moveable die 12moves relative to the stationary die 10 in the direction of the arrows14 in FIGS. 2 and 4 to define a rolling cycle. As the workpiece rollslongitudinally between the starting and final ends 16, 18 of thestationary die 10, a thread is formed on the workpiece.

As illustrated in FIGS. 2 and 4, the dies 10, 12 each have opposingfaces 20, 22 configured with ridges and grooves which form the threadsand define, for example, the pitch, major diameter, minor diameter andthread type of the finished screw. The dies 10, 12 during each rollingcycle cooperatively gradually penetrate the workpiece to form thefinished screw. The dies 10, 12 are configured so that the least amountof rolling work as possible is done in the dwell section to maximize thelife of the die.

A starter finger (not illustrated) engages the workpiece blank to ensurethat the moving die 12 picks up the blank and starts the rollingprocess. For most applications, as the workpiece starts at the startingend 16, 24 of each die 10, 12, the threads are deep and sharp. In thedwell sections 26, 28, the threads are flat and shallower. The startingend threads are sharp for easier penetration as the screw starts to rolland get progressively wider along the die length until they ultimatelyreach width and depth equal to the desired finished thread form. Thedies 10, 12 are aligned or “matched” to produce the proper optimumthread continuum. The final die form is termed the dwell section 26, 28and extends along the die 10, 12 for distance long enough to properlydimension the screw. The thread and tip are fully developed just priorto parting the dies.

For each rolling cycle there is an associated pressure cycle. Asdescribed above, the sharpness of the threads and the thread width varyalong the length of the dies 10, 12. Consequently, the pressure forcewhich is exerted on the workpiece by the dies 10, 12 varies as theworkpiece progresses through the rolling cycle. An ideal pressure cyclemay be calculated and compared to the observed pressure cycle of anoperating thread rolling system as a means of monitoring itsperformance. For example, the IMPAX/SK 3000 ™ process monitoring systemmonitors and displays the rolling pressure force over each rolling cycleof the thread rolling system. The ideal pressure cycle is displayedsimultaneously so that the operator is provided with real-timeinformation on deviation from optimum system operating conditions.

The IMPAX/SK 3000 ™ process monitoring system utilizes a piezo-electricsensing device mounted in a die adjusting block to sense the pressureexerted on the workpiece by the dies. Other conventional thread rollingsystem process monitoring systems may utilize other sensors and locatethese sensors in the die block, the frame, or the yoke.

Conventional process monitoring systems may be utilized in severaldifferent ways. A persistent deviation between the measured pressurecycle and the ideal pressure cycle generally indicates that the threadrolling system setup is improper. When this occurs, the operator mayadjust the thread rolling system setup to minimize or eliminate suchdeviations and thereby optimize the system performance. A deviation mayindicate that a faulty screw was produced during the rolling cycle inwhich the deviation was observed. When this occurs, the operator maycheck the output of the thread rolling system to verify the quality ofthe product.

With reference to FIGS. 1 and 2, a first embodiment 30 of a machine toolsystem in accordance with the invention includes a cold forming tool 32,such as a pair of flat thread rolling dies 10, 12, having an embeddedelectronic device such as a microchip 34. Preferably, the microchip 34is positioned in a recess 36 in the stationary die 10 and is mountedwithin the recess 36 by a sealant material 38, such as potting compoundor epoxy, which seals the recess 36 against infiltration by particulatematter and liquids. An antenna 40 extending from the microchip 34 mayalso be disposed within the sealant material 38. Alternatively, anelectrical or fiber optic lead 42 may extend from the microchip 34,through the sealant material 38, to at least the surface of thestationary die 10.

The microchip 34 includes at least a memory portion 44 and a datatransmission portion 46. The memory portion 44 has sufficient storagecapacity to store tool identification and design data which does notchange over the lifetime of the tool and tool operating data which isupdated as the tool is used in the manufacturing process. Permanent tooldata for a thread rolling die set may include the customer part number,the manufacturer part number, manufacturing information, setupinformation such as an optimum rolling force curve, and the effectivelifetime expressed as a number of rolling cycles. Operating data for athread rolling die set 10, 12 may include the date/time of each set-up,the date/time of each run, the number of rolling cycles in each run, thenumber of set-up adjustments in each run, abnormal force incidents, wearpattern documentation by run, and the tool life remaining expressed as anumber of rolling cycles. The microchip 34 stores the permanent data andthe operating data and communicates this data when queried by anelectronic reader. The data transmission portion 46 includes all circuitcomponents and/or software that is required to transmit and receive theoperating data. It should be appreciated that any electronic devicehaving at least the memory and data transmission portions 44, 46described above and which is small enough and rugged enough to beembedded on a cold forming tool 32 may be used in the present invention.

The cold forming machine 48 in which the cold forming tool 32 is mountedincludes a process monitoring system 50 having an electronic reader 52,which communicates with the microchip 34 embedded in the cold formingtool 32. Such communication may be by microwave, Rf, infrared, or othercommon radiation of the electromagnetic spectrum. The process monitoringsystem 50 also includes sensors 54 for detecting various operatingparameters of the cold forming tool 32. The sensors 54 may include asensor, such as a piezo electric sensor capable of sensing the pressurecycle, for detecting operation of the cold forming tool, a temperaturesensor for measuring the temperature of the cold forming tool, or a flowdetector for monitoring coolant flow to the cold forming tool. Theprocess monitoring system 50 may also include a key pad 56 for inputtingdata, a monitor 58 for displaying process information, such as thepressure cycle and a data output 60 to a master scheduler system or amachine control system. The process monitoring system sensors 54 and/orthe process monitoring system key pad 56 are utilized to input all theparameters which are recorded in the microchip 34. A microprocessor 62in the process monitoring system 50 performs any calculations which arenecessary to convert the input signals or transform the sensed orinputted data into the form required for storage in the microchip 34.For example, microprocessor 62 calculates the remaining effectivelifetime of the cold forming tool 32 based on the output of the sensor54 which detects operation of the cold forming tool 32 and the expectedlife data and prior use data stored in microchip 34.

Preferably, the data/query signal received by the data transmissionportion 46 of the microchip 34 provides the power required by themicrochip 34 to record the data or respond to the query and therefore anexternal power source is not required. If the data/query signal does notprovide sufficient power, an external power source may be used. Abattery mounted in the recess 36 may be used as the external powersource. Machine generated vibration power may be utilized as well.Alternatively, a data/power connection may be provided between theprocess monitoring system 50 and microchip via electrical lead 42. If anexternal power source is utilized, the microchip 34 may be used toperform more power intensive functions. For example, the calculationsperformed by microprocessor 62 could be performed by microchip 34.

With reference to FIG. 5, the machine tool system also includes aportable, hand-held electronic reader 64. The hand-held electronicreader 64 includes a communications portion 66, comprising the circuitcomponents and/or software which are required to send and receive dataand query signals, a data transmission interface 68 for sending andreceiving signals to microchip 34, and a data transmission interface 70for transmitting the stored data to the central control system or someother central monitoring system. The hand-held electronic reader 64 alsoincludes memory 72 for storing the data received in response to thequery and may include a display 74 for viewing the data received frommicrochip 34.

The hand-held electronic reader 64 provides flexibility to the subjectmachine tool system 30, 30′. For example, if the display 58 of theprocess monitoring system 50 is at a location which is remote from thecold forming tool 32, the hand-held electronic reader 64 allows theoperator to query and view the stored data while he is at the coldforming tool 32.

In addition to the cold forming tools 32 which are in use at any momentin time in the cold forming machines 48, most manufacturers also have atool crib which contains tools 32 which are not actively in use. Whenthe production run of a first type of screw is completed, the first dieset 10, 12 (which had been used to produce the first type of screw) isremoved from the cold forming machine, a second die set 10, 12 designedfor producing the second type of screw is removed from the tool crib andmounted in the cold forming machine 48, and the cold forming machine 48commences the production run of the second type of screw. If the firstdie set 10, 12 has not reached the end of its effective lifetime, it isplaced in the tool crib for use in the next production run of the firsttype of screw. If the first die set 10, 12 has reached the end of itseffective lifetime, it is discarded, a new first die set 10, 12 ispurchased and placed in the tool crib. Therefore, the tool cribgenerally contains new die sets and used die sets. With goodadministrative controls, a manufacturer can easily know which coldforming tools 32 are installed in the cold forming machines 48 and whichcold forming tools 32 are stored in the tool crib. However, it is moredifficult for the manufacturer to know which cold forming tools 32 arenew and which are used and much more difficult for the manufacturer toknow how many more parts may be produced by any one of the used coldforming tools 32.

The hand-held electronic reader 64 and imbedded microchip 34 provide ameans for easily conducting and maintaining an accurate inventory of themanufacturers' cold forming tools 32. More importantly, an inventoryconducted with the subject the hand-held electronic reader 64 andimbedded microchip 34 includes easily accessible and up to the minuteinformation on the operating history of each of the cold forming tools32 and the tool remaining life. To conduct the inventory, the usermerely passes the hand-held electronic reader 64 by each cold formingtool 32. During each pass, the reader 64 queries the tool 32, the tool32 transmits data stored in the microchip 34, and the transmitted datais stored in memory 72. Depending on the capacity of the memory 72, theamount of data which is received from each tool 32, and the number oftools 32 which must be inventoried, the stored data is downloaded to thecentral computer periodically during the inventory or at the end of theinventory, and the central computer compiles an inventory list. The dataquery may be customized depending on the needs of a particularinventory. It should be appreciated that the accuracy and ease of use ofthis method of inventory is dependent on the microchip 34 which isembedded in and inseparable from each cold forming tool 32.

The embodiment 30′ illustrated in FIGS. 3 and 4 is very similar to thefirst embodiment 30 with the primary exception that a sensing device 76,such as a piezo electric device, is mounted in the recess 36 and incommunication with the microchip 34. Consequently, the sensing devicesignal may be received directly by the microchip 34 instead of by way ofthe microprocessor 62′ in the process monitoring system. Preferably, thesensing device signal provides the power required by the microchip 34 torecord the data. Alternatively, an external power source such as abattery or an electrical connection with the microprocessor may be used.Similar to the first embodiment, the microchip 34 may perform anyrequired calculations and data conversion if an external power source isutilized. Otherwise, the process monitoring system microprocessor 62′performs the required calculations and data conversion. The processmonitoring system includes an electronic reader 52′, additional sensors,a key pad 56′, a monitor 58′, and a data output 60′ to a masterscheduler system or a machine control system.

FIGS. 6 a through 6 d show the basic sequence of actions in a standardtype solid die, double stroke heading machine. In FIG. 6 a, wire 78 isshown being fed through the cut off die 80 until it reaches the wirestop 82. By adjusting the location of this stop 82, the operatordetermines the length of the blank 86.

In FIG. 6 b, the cutoff knife 84 has already cut the blank 86 from thecoil and carried it (the blank) to the heading die 88. The knife strokeis set to stop when the blank 86 is centered on the heading die 88.

In FIG. 6 c, the first punch 90 comes forward for the first blow. Thefirst and second punches 90, 92 are both carried on the ram or gate 94(both terms are commonly used). As the first punch 90 begins its forwardstroke, it pushes the blank 86 into the heading die 88, right up againstthe knockout pin 96 (if no extrusion is being done). At this point theblank 86 is subjected to the full force of the first punch 90, andbegins to flow into its new shape. As the first blow is completed, theextrusion, if any, is done, and the head has been upset into the coneshape, ready for final shaping.

With reference to FIG. 6 d, the cam-operated mechanism shifts thepunches 90, 92 after the first blow, so that the second punch 92 isaligned with the heading die 88. The gate 94 comes forward again, thesecond or finish blow, is struck, and the gate 94 withdraws. As itwithdraws, the punches 90, 92 are now shifted so that the first, or conepunch 90, is again in position for the new blank. Meanwhile, as the gate94 is withdrawing, the knockout pin 96 comes forward all the way to theface of the die 88, forcing the finished part 98 out ahead of it. As thegate 94 reaches its fully withdrawn position, the finished part 98 isejected and falls into a collection bin 100. The cutoff knife 84 isalready starting to move a new blank into position, ready to begin thecycle all over again.

As shown in FIGS. 6 c and 6 d, a sensor 102, 102′ and a microchip 104,104′ are mounted in a recess in each of the gate 94 and heading die 88.The sensors 102, 102′ detect each operation of the cold heading tool andtransmit a signal to a process monitoring system for use by the systemand for storage in the microchip 104, 104′.

With reference to FIG. 7, gundrilling is a metal removal processutilizing a drilling machine 108, a high pressure coolant system 110,and a single or a two flute gundrill 112. The gundrilling process is acontrolled operation which offers size, location, finish, andstraightness accuracy where critical tolerances are important. Addedbenefits are scrap reduction, burr-free holes, bottom forming, and blindholes, as well as entry with surfaces other than 90 degrees.Repeatability makes this application feasible on numerically controlledequipment.

In addition to dedicated gundrilling machines 108, gundrills 112 andcoolant systems 110 are easily integrated with CNC machining centers,lathes, and milling machines, providing users with all the benefits ofthe process for a relatively small investment. Incorporating gundrills112 on other types of machinery often requires a short (1 to 2 diametersdeep) starter hole to be used in place of the gundrilling machine'sstarter bushing 116. The gundrill tip 114 is then fed Into thepredrilled hole before engaging the spindle.

The gundrill 112 is a simple, basic tool with three essential parts: thetip 114, the shank 118, and the driver 120. These parts are brazedtogether into one correctly aligned unit.

The tip 114 is the most critical of the three elements. The tip 114 cutsthe hole and maintains precision as it pilots the drill through thepart, producing precision holes in one pass. The point or nosegrind hastwo basic angles that may be varied for optimum results depending on thematerial to be drilled. These angles must balance the cutting forces,distributing them to the tip's bearing pads to keep the drillconcentric. The tip 114 is slightly larger in diameter than the shank,thus enabling the shank 118 to rotate freely without contacting the holewall. Through the tip 114 is an oil hole which lines up with the shank'soil channel to facilitate correct flow of coolant at high pressures tothe cutting edge.

As shown in FIG. 7, a sensor 122 and a microchip 124 are mounted in arecess 126 in the gundrill 112. The sensor 122 detects each operation ofthe gundrill 112 and transmits a signal to a process monitoring systemfor use by the system and for storage in the microchip 124.

It should be appreciated that the heading, threading, and gundrillingmachine tools described above may include sensors, other than the loadsensors, for monitoring additional system parameters. For example,sensors 128, 130, 132 may also be located in other components of thegundrilling system, as shown in FIG. 7. Sensors 128 in the coolantsystem 110 may be provided to sense coolant flow and/or temperature.

While preferred embodiments have been shown and described, variousmodifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustration and not limitation.

1. A machine tool system comprising: a tool for cold forming a workpieceover an operating cycle, the tool having an electronic device fixedlymounted thereto, the electronic device having means for storing dataincluding identification data for the tool and operating data for thetool; a sensor device which senses each operating cycle of the tool; andat least one interface device in communication with the electronicdevice and the sensor device.
 2. The machine tool system of claim 1further comprising a sealant material, the tool having an exteriorsurface and defining a recess extending from the surface, the electronicdevice being disposed within the recess and encased by the sealantmaterial, the electronic device having an antenna extending within thesealant material.
 3. The machine tool system of claim 1 furthercomprising a sealant material, the tool having an exterior surface anddefining a recess extending from the surface, the electronic devicebeing disposed within the recess and encased by the sealant material,the electronic device having a fiber optic lead extending through thesealant material to at least the surface of the tool.
 4. The machinetool system of claim 1 wherein the at least one interface deviceincludes a process monitoring system having a key pad, a monitor, and amicroprocessor.
 5. The machine tool system of claim 4 wherein theprocess monitoring system also includes a temperature sensor formeasuring the temperature of the tool.
 6. The machine tool systen ofclaim 4 wherein the tool also has a cooling system carrying a flow ofcoolant through the tool and the process monitoring system also includesa flow detector for monitoring the flow of coolant.
 7. The machine toolsystem of claim 4 wherein the at least one interface device alsoincludes a portable electronic reader.
 8. The machine tool system ofclaim 7 wherein the portable electronic reader includes a first datatransmission interface for sending and receiving signals to theelectronic device, memory for storing the signals received from theelectronic device, and a second data transmission interface fortransmitting the stored signals to the process monitoring system.
 9. Themachine tool system of claim 8 wherein the portable electronic readeralso includes a display for viewing the signals received from theelectronic device.
 10. The machine tool system of claim 1 wherein theelectronic device and the interface device each have a communicationportion, the communication portion of the interface device includingmeans for transmitting a data/query signal, the communication portion ofthe electronic device having means for receiving the data/query signaland powering the means for storing data with the data/query signal. 11.The machine tool system of claim 1 further comprising a power sourcemounted to the tool.
 12. The machine tool system of claim 1 wherein thetool includes a punch, a die, and a ram, the sensor device comprisesfirst and second sensors, and the electronic device comprises a firstmicrochip, the die and ram each defining a recess, the first sensor andthe first microchip being mounted within the recess of the die, thesecond sensor being mounted within the recess of the ram.
 13. Themachine tool system of claim 12 wherein the electronic device alsocomprises a second microchip mounted within the recess of the ram. 14.The machine tool system of claim 1 wherein the tool is a gundrilldefining a recess, the sensor being mounted within the recess of thegundrill.
 15. The machine tool system of claim 14 wherein the electronicdevice is mounted within the recess of the gundrill.
 16. The machinetoot system of claim 1 wherein the identification data for th.e tool isselected from customer part number, manufacturer part number,manufacturing information, set-up information, effective lifetime, andany combination thereof.
 17. The machine tool system of claim 16 whereinthe set-up information comprises an optimum rolling force curve.
 18. Themachine tool system of claim 16 wherein the effective lifetime is apredetermined number of rolling cycles.
 19. The machine tool system ofclaim 1 wherein the operating data for the tool is selected fromdate/time of each set-up, date/time of each run, number of rollingcycles experienced in each run, number of set-up adjustments experiencedin each run, abnormal force incidents, wear pattern by run, tool liferemaining, and any combination thereof.
 20. The machine tool system ofclaim 19 wherein the tool life remaining is computed by subtracting thenumber of rolling cycles experienced by the tool from a predeterminednumber of rolling cycles.
 21. The machine tool system of claim 10wherein there are no other sources of power connected to the electronicdevice.
 22. The machine tool system of claim 11 wherein the power sourceis a battery.
 23. The machine tool system of claim 11 wherein the sensordevice is a piezo electric device, said piezo electric device emitting asignal indicative of the operating cycle of the tool, said signalpowering the means for storing data, whereby said piezo electric deviceis the power source.
 24. A method of monitoring the life cycle of a coldforming tool in a cold forming system, the tool having an electronicdevice fixedly mounted thereto, the method comprising the steps of:storing identification data for the tool in the electronic device;sensing each operating cycle of the tool with an operating cycle sensordevice and transmitting operating cycle data from the operating signalsensor device; and receiving and storing the operating cycle data in theelectronic device.
 25. The method of claim 24 wherein the cold formingsystem also has a process monitoring system, the method furthercomprising the steps of: receiving the operating cycle data in theprocess monitoring system; and transmitting the operating cycle datafrom the process monitoring system to the electronic device.
 26. Themethod of claim 25 wherein the cold forming system further has atemperature sensor, the method further comprising the steps of: sensingthe temperature of the tool; and transmitting a signal corresponding tothe sensed temperature of the tool to the process monitoring system. 27.The method of claim 25 further comprising the steps of: accessing theidentificadon data and the operating cycle data stored in the,electronic device with the process monitoring system; and displaying theidentification data and the operating cycle data at the processmonitoring system.
 28. The method of claim 24 further comprising thestep of accessing the identification data and the operating cycle datastored in the electronic device with a portable reader.
 29. The methodof claim 28 further comprising the step of recording the identificationdata and operating cycle data in the portable reader.
 30. The method ofclaim 28 further comprising the step of displaying the identificationdata and operating cycle data at the portable reader.
 31. The method ofclaim 24 further comprising the steps of: determining the expectednumber of operating cycles over the lifetime of the tool; accessing theidentification data and the operating cycle data stored in theelectronic device; calculating the number of operating cycles that thetool has been used from the operating cycle data; and subtracting thenumber of operating cycles that the tool has been used from the expectednumber of operating cycles over the lifetime of the tool to determinethe remaining lifetime of the tool.